dejvino/PinePhoneBoy
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PinePhoneBoy/main.scad

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// dependency: https://github.com/revarbat/BOSL
include <BOSL/constants.scad>
use <BOSL/transforms.scad>
use <BOSL/shapes.scad>
use <BOSL/masks.scad>
use <BOSL/sliders.scad>
// DEBUG:
//validation = 1;
//xray = 1;
// EXPORT:
MODEL_HARNESS_LEFT=1;
MODEL_HARNESS_RIGHT=2;
MODEL_HARNESS_TOP=3;
MODEL_HARNESS_SLIDER_FRONT=4;
MODEL_HARNESS_SLIDER_BACK=5;
export=1; // [0:5]
function is_not_export() = is_undef(export) || export == 0;
function is_export() = !is_not_export();
function is_model_strict(m) = is_export() && export == m;
function is_model(m) = is_not_export() || export == m;
function get_phone_size() = [160, 76.7, 10];
module cubi(s, fillet=0, edges=EDGES_ALL) {
if ($preview) {
cube(s, center=true);
} else {
cuboid(s, fillet=fillet, edges=edges);
}
}
module phone() {
s=get_phone_size();
color("gray")
cubi(s, fillet=5);
}
module arm() {
$fn=6;
s=[210, 55, 50];
color("SaddleBrown")
down(s.z/2 + get_phone_size().z/2) cubi(s, fillet=20);
}
module phone_harness() {
ops=get_phone_size();
ps=[ops.x+0.2, ops.y+0.2, ops.z+0.2];
shell_wall=3;
shell_rim_wall=3;
rim_edge_thickness=1.2;
rim_edge_tolerance=0.4;
expose_back_camera=false;
screwmount_screw=3;
harness_divider=[16, 0, 1.3];
harness_size=[ps.x+shell_wall*2, ps.y+shell_wall*2, ps.z+shell_wall*2];
rim_size=[harness_size.x+2*shell_rim_wall, harness_size.y+2*shell_rim_wall, 6];
w=shell_wall;
f=2;
rf=5;
hs=harness_size;
backplane_rim_size=[30, ps.y*0.95, shell_wall/2];
// ==== SHELL ====
module shell() {
$fn = $preview ? 6 : 30;
difference() {
cubi(hs, fillet=f);
cubi(ps, fillet=f);
}
shell_rim();
shell_screwmounts();
}
module shell_rim() {
$fn = $preview ? 6 : 30;
w=shell_rim_wall;
s=rim_size;
intersection() {
difference() {
cubi(s, fillet=rf, edges=EDGES_Z_ALL);
cubi(ps, fillet=f, edges=EDGES_Z_ALL);
}
cubi(s, fillet=1);
}
rail_extension=10;
fwd(hs.y/2) xrot(90) harness_rail(slider_len_front+rail_extension);
back(hs.y/2) xrot(-90) harness_rail(slider_len_back+rail_extension);
}
module shell_rim_edge(thickness, groove, tolerance=rim_edge_tolerance) {
$fn = $preview ? 6 : 30;
w=thickness + (groove ? tolerance : 0);
offset=(groove ? 0 : tolerance/2);
res=[hs.x+2*(w+offset), hs.y+2*(w+offset), 3];
resi=[hs.x+2*offset, hs.y+2*offset, res.z+1];
up(0.0) difference() {
intersection() {
cubi(res, fillet=rf, edges=EDGES_Z_ALL);
cubi(res, fillet=(groove?1:1.5), edges=EDGES_BOTTOM);
}
cubi(resi, fillet=rf, edges=EDGES_Z_ALL);
}
}
module foreach_screwmount() {
for(x = [0:1]) for (y = [0:1]) {
translate([(-0.5+x)*ps.x, (-0.5+y)*ps.y, -hs.z/2])
children();
}
}
module shell_screwmounts() {
$fn = $preview ? 6 : 30;
r=3;
foreach_screwmount() {
cylinder(r=r, h=hs.z);
}
}
module shell_screwmounts_holes() {
$fn = $preview ? 6 : 30;
foreach_screwmount() {
up(w) cylinder(d2=screwmount_screw, d1=screwmount_screw*0.5, h=hs.z+1);
up(hs.z-1) cylinder(d=screwmount_screw+1.5, h=5);
}
}
module shell_backplane(groove) {
down(hs.z/2 - shell_wall/6) up(backplane_rim_size.z/2) right(harness_divider.x) scale(groove ? 1.01 : 1) cubi(backplane_rim_size, fillet=5, edges=EDGES_Z_LF);
}
// ==== SHELL SLIDER AND RAIL ====
rail_angle=36;
rail_wall=1;
slider_slop=0.1;
slider_len_back=hs.x*0.3;
slider_len_front=hs.x*0.3;
module harness_slider(l) {
base=2;
ss=[l, shell_rim_wall, rim_size.z+rail_wall*2];
up(ss.y + base) xrot(180) slider(l=ss.x, w=ss.z, h=ss.y, base=base, chamfer=0.9, wall=2, ang=rail_angle, slop=slider_slop, orient=ORIENT_X, align=V_UP);
}
module harness_rail(l) {
sw=2;
ss=[l, shell_rim_wall, rim_size.z+rail_wall*2];
rail(l=ss.x, w=ss.z, h=ss.y, chamfer=0.5, ang=rail_angle, orient=ORIENT_X, align=V_UP);
}
// ==== SHELL CUTOUTS ====
module shell_cutouts() {
top_cutout();
bottom_cutout();
left_cutout();
right_cutout();
front_cutout();
shell_screwmounts_holes();
}
// -- TOP --
module screen_cutout() {
s=[138, 69, 100];
up(s.z/2) cubi(s, fillet=3, edges=EDGES_Z_ALL);
}
top_offset=6.5;
module top_speaker_cutout() {
s=[3, 12, 100];
right(ps.x/2 - top_offset) up(s.z/2 - ps.z/3) cubi(s, fillet=1);
}
module front_camera_cutout() {
$fn = $preview ? 6 : 30;
d=5;
s=[d, d, 100];
right(ps.x/2 - top_offset) fwd(11.5) cylinder(d=s.x, h=s.z);
}
module leds_cutout() {
s=[4, 14, 100];
right(ps.x/2 - top_offset) up(s.z/2 - ps.z/3) back(23) cubi(s, fillet=1);
}
module top_cutout() {
screen_cutout();
top_speaker_cutout();
front_camera_cutout();
leds_cutout();
}
// -- BOTTOM --
module back_camera_cutout() {
s=[13, 25, expose_back_camera ? 100 : 11];
right(ps.x/2 - 7.5) fwd(ps.y/2 - 23) down(s.z/2 - ps.z/3) cubi(s, fillet=6, edges=EDGES_Z_ALL);
}
module bottom_speaker_cutout() {
s=[8, 49, 100];
left(ps.x/2 - 13)
difference() {
down(s.z/2 - ps.z/3) cubi(s, fillet=1);
bars=8;
down(ps.z/2)
for (i = [0:bars-1]) {
bs=[s.x+2, 1, 2];
step=s.y/bars;
fwd(i*step - s.y/2 + step/2) down(w) cube(bs, center=true);
}
}
}
module bottom_cutout() {
back_camera_cutout();
bottom_speaker_cutout();
}
// -- RIGHT --
module headphones_cutout() {
$fn = $preview ? 10 : 30;
d1=8.8;
d2=14;
p=[ps.x/2, ps.y/2-24, -0.88];
h=30;
translate(p) yrot(90) down(10) cylinder(h=h, d1=d1, d2=d2);
}
module right_cutout() {
headphones_cutout();
}
// -- LEFT --
module usbc_cutout() {
s=[20, 20, 7];
left(ps.x/2) down(2) cubi(s, fillet=1);
}
module left_cutout() {
usbc_cutout();
}
// -- FRONT --
module buttons_cutout() {
s=[42, 100, 5];
fwd(ps.y/2) right(ps.x/2 - 44.5) cubi(s, fillet=1);
}
module front_cutout() {
buttons_cutout();
}
// ==== MODEL ====
divider=harness_divider;
module model_harness_left() {
intersection() {
intersection() {
translate(divider) downcube([1000, 1000, 1000]);
translate(divider) leftcube([1000, 1000, 1000]);
}
difference() {
shell();
shell_rim_edge(rim_edge_thickness, groove=true, tolerance=rim_edge_tolerance);
shell_cutouts();
shell_backplane(groove=true);
}
}
}
module model_harness_right() {
intersection() {
intersection() {
translate(divider) downcube([1000, 1000, 1000]);
translate(divider) rightcube([1000, 1000, 1000]);
}
difference() {
shell();
shell_rim_edge(rim_edge_thickness, groove=true, tolerance=rim_edge_tolerance);
shell_cutouts();
}
}
shell_backplane(groove=false);
}
module model_harness_top() {
intersection() {
translate(divider) upcube([1000, 1000, 1000]);
difference() {
shell();
shell_cutouts();
}
}
difference() {
shell_rim_edge(rim_edge_thickness, groove=false);
shell_cutouts();
}
}
module model_harness_slider_front() {
difference() {
fwd(hs.y/2) xrot(90) harness_slider(slider_len_front);
front_cutout();
}
}
module model_harness_slider_back() {
back(hs.y/2) xrot(-90) harness_slider(slider_len_back);
}
if (is_model(MODEL_HARNESS_LEFT)) model_harness_left();
if (is_model(MODEL_HARNESS_RIGHT)) model_harness_right();
if (is_model(MODEL_HARNESS_TOP)) model_harness_top();
if (is_model(MODEL_HARNESS_SLIDER_FRONT)) model_harness_slider_front();
if (is_model(MODEL_HARNESS_SLIDER_BACK)) model_harness_slider_back();
}
module model() {
phone_harness();
}
if (!is_undef(validation)) {
intersection() {
phone();
model();
}
} else {
intersection() {
if (!is_undef(xray)) {
span_cube([0,1000*xray], [0,1000*xray], [-1000,1000]);
}
union() {
if (is_not_export()) {
//phone();
//arm();
}
model();
}
}
}
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